Control Line Set ESP Packer With Anti-Preset Device

ABSTRACT

An apparatus and method of this disclosure include a downhole tool containing an anti-preset device in communication with a setting chamber configured to actuate at least one tool set feature of the downhole tool such as a cone-and-slip arrangement. The anti-preset device includes a control line with a port to setting chamber and a first rupture disk that prevents a control line fluid from passing through the port to the setting chamber until a first predetermined fluid pressure is achieved in the control line, the first predetermined fluid pressure being a burst pressure of the first rupture disk and achieved when the downhole tool is a desired depth with a wellbore.

CROSS-REFERENCE TO CO-PENDING APPLICATIONS

This application claims priority to, and the benefit of, U.S. 62/734,012 filed Sep. 20, 2018.

BACKGROUND

This disclosure is in the field of downhole tools used in the completion of oil and gas wells. More specifically, the disclosure is in the field of packers that seal the annulus between a tubing string and the well casing and include means to prevent the packer from being actuated prematurely during its deployment downhole.

Prior art means for hydraulically or hydrostatically setting production packers and other types of downhole tools is discussed in U.S. Pat. No. 7,717,183 B2 to Ezell et al. Other prior art means for setting production packers and other types of downhole tools include electro-hydraulic means and electronic setting means.

The '183 patent listed above further discloses means that include a rupture disk that bursts when annulus pressure exceeds a burst pressure, allowing the fluid to actuate a top-down piston. However, the method requires the use of plugs. In applications where the well bore is on a vacuum, annulus pressure cannot be increased.

SUMMARY

Embodiments of a downhole tool of this disclosure may include a setting chamber configured to actuate at least one tool set feature of the downhole tool; a control line including a port configured for fluid communication with the setting chamber; the control line further including a rupture disk configured to prevent a control line fluid from passing through the port to the setting chamber until a predetermined fluid pressure is achieved in the control line, the predetermined fluid pressure being a burst pressure of the rupture disk. Embodiments of a method of actuating a downhole tool of this disclosure includes:

-   -   connecting a control line of the downhole tool to a pump located         at surface; the control line including a port configured for         fluid communication with a setting chamber of the downhole tool,         the setting chamber configured to actuate at least one tool set         feature of the downhole tool;     -   running the downhole tool to a desired depth within the         wellbore;     -   filling the control line with a control line fluid;     -   pressurizing, by way of the pump, the control line fluid to a         first predetermined fluid pressure;     -   preventing the control line fluid from passing through the port         to the setting chamber until the first predetermined fluid         pressure is achieved in the control line, the preventing being         done by way of a first rupture disk having a predetermined burst         pressure equal to the first predetermined fluid pressure; and         after the first rupture disk bursts, the setting chamber moving         in response to the control line fluid and actuating the at least         one tool set feature.

In embodiments, the setting chamber may be bi-directional, moving down and up during the actuating. The tool set feature may be a cone-and-slip arrangement. In embodiments, the downhole tool may be a packer, the packer elements being actuated by the cone-and-slip arrangement. No production tubing or annulus pressure is used. The control line pressure may exceed that of the tubing or annulus pressure. In embodiments, no valves, electronic trigger mechanisms, or electronically activated setting module is required to set the tool.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an end view embodiment of a multi-string packer configured for use with an electric submersible pump (“ESP”).

FIG. 1B is a view taken along section line 1-1 of FIG. 1A.

FIG. 2 is a view of the packer of FIG. 1 taken along section line 2-2. The left side of the drawing is the uphole side of the packer, the right side is the downhole side of the packer.

FIG. 3 is view of the packer of FIG. 1 taken along section line 3-3.

FIG. 4 is view of the packer of FIG. 1 taken along section line 4-4.

FIG. 5 is view of the packer of FIG. 1 taken along section line 5-5 of FIG. 2.

FIG. 6 is view of the packer of FIG. 1 taken along section line 6-6 of FIG. 2.

FIG. 7 is view of the packer of FIG. 1 taken along section line 7-7 of FIG. 3.

FIG. 8 is view of the packer of FIG. 1 taken along section line 8-8 of FIG. 2.

FIG. 9 is view of an embodiment of the anti-preset device taken along section 9 of packer of FIGS. 5 and 10.

FIG. 10 is an enlarged partial view of the packer of FIG. 1 taken along section 59 of FIGS. 5 and 10.

ELEMENTS AND NUMBERING USED IN THE DRAWINGS

-   1 Flat top -   2 Top sub -   3 Handling pup -   4 Long string mandrel -   5 Short string mandrel -   6 Upper cone -   7 Upper slip cage -   8 Upper slip -   9 Left element rubber -   10 Element 70D rubber -   11 Setting mandrel -   12 Setting chamber -   13 Lower cone -   14 Lower slip cage -   15 Lower slips -   16 Lower slip cage cap -   17 Shear screws -   18 Tapered slip spring -   19 Socket cap screw -   20 Pick-up ring -   21 O-ring -   22 O-ring -   23 O-ring -   24 O-ring -   25 O-ring -   26 O-ring -   27 O-ring -   28 Pup joint -   29 Feed through tube -   30 Feed through tube -   31 Lock ring -   32 Long string bottom sub -   33 Shear screw -   34 Shear sleeve -   35 Changeover -   36 Rupture disk -   37 Upper slip -   38 Releasing slip -   39 Right element rubber -   40 Button head socket cap screw -   41 Slip spring -   42 Control line port to surface -   43 Setting chamber area -   44 Control line to setting chamber

DETAILED DESCRIPTION

Embodiments of a downhole tool of this disclosure include an anti-preset device that provides a fail-safe method that prevents the tool from setting downhole until operator-ready for setting. By way of a non-limiting example, the tool may be a packer. In some embodiments, the packer may be a multi-string packer configured for use with an electric submersible pump (“ESP”).

In embodiments, the anti-preset device may comprise a control line 44 including a port 42 in communication with a setting chamber 12 of the downhole tool, the control line 44 further including a rupture disk 36 configured to prevent a control line fluid from passing through the port 42 to the setting chamber 12 until a predetermined fluid pressure is achieved, the predetermined fluid pressure rupturing the rupture disk 36. The setting chamber 12 may be configured for use with a setting mechanism such as, but not limited to, a setting mandrel 11 that actuates a cone-and-slip arrangement 13, 15. Setting chamber 12 moves up and down during the setting of the cones and slips 13, 15. In some embodiments, the setting mechanism may lock in any setting movement, so bleeding the pressure down on the control line 44 and setting chamber 12 will not unset or deactivate the tool once the initiation shear screws 17 have been sheared and the tool has begun to set.

In embodiments, the control line 44 is a fluid conduit. One end of the conduit is above the surface, the other end being connected to the tool. The fluid may be pumped through the line 44 under pressure or it may be gravity-fed. The line 44 may be filled with the fluid prior to the tool being run downhole or after the tool has been run downhole. In embodiments, the control line 44 may be surface-actuated, the control line 44 being connected to a pump of a kind known in the art and configured to build fluid pressure in the line 44 effective for bursting the disk 44. In other embodiments, the line 44 may be gravity-fed, the pressure head at the desired set depth of the tool being effective for bursting the disk 36.

The control line fluid may be hydraulic fluid. The line 44 may be sized to run through an internal string feed of the downhole tool. In other embodiments, the line 44 may run along an outside diameter of the tool. Regardless of where the line 44 is run, the line 44 may be sized to provide, for a given fluid, the needed pressure head to burst the disk 36 at the predetermined value for setting the tool at its predetermined depth. In some embodiments, the control line 44 is a ¼-inch stainless steel line. Until the disk 36 ruptures, ambient downhole pressure may be relied upon to prevent actuation of the cones and slips 13, 15.

The burst pressure of the disk 36 may be in a range of a predetermined value. By way of a non-limiting example, the rupture disk 36 may be disk having a rupture or burst pressure in a range of 3,200 psi to 3,600 psi. A rupture disk 36 having a different burst pressure range than this may be used. Two or more rupture disks 36 may be included in series, each having a same or different burst pressure rating than the other.

In some embodiments the burst pressure is in the range of 500 psi to 10,000 psi, there being sub- and sub-sub ranges within this broader range. In other embodiments the burst pressure range is above 10,000 psi. The burst pressure of the disk may be in a range of 500 psi to 1,000 psi; 1,000 psi to 1500 psi; 1,500 psi to 2,000 psi; 2,000 psi to 2,500 psi; 2,500 psi to 3,000 psi; 3,000 psi to 3,500 psi; 3,500 psi to 4,000 psi; 4,000 psi to 4,500 psi; 4,500 psi to 5,000 psi; 5,000 psi to 5,500 psi; 5,500 psi to 6,000 psi; 6,000 psi to 6,500 psi; 6,500 psi to 7,000 psi; 7,000 psi to 7,500 psi; 7500 psi to 8,000 psi; 8,000 psi to 8,500 psi; 8500 psi to 9,000 psi; 9,000 psi to 9,500 psi; 9,500 psi to 10,000 psi; 10,000 psi to 10500 psi; 10,500 psi to 11,000 psi; 11,000 psi to 11,500 psi; 11500 psi to 12,000 psi; 12,000 psi to 12500 psi; 12,500 psi to 13,000 psi; 13,000 psi to 13,500 psi; 13,500 psi to 14,000 psi; 14,000 psi to 14,500 psi; 14,500 psi to 15,000 psi; there being broader ranges that span all, or a portion of, these ranges.

While embodiments of an anti-set device for a downhole tool have been described here, modifications may be made without departing from the scope of the following claims. Each recited element of the claims is entitled to its full range of equivalents. 

1. A downhole tool comprising: a setting chamber configured to actuate at least one tool set feature of the downhole tool; a control line including a port configured for fluid communication with the setting chamber; the control line further including a first rupture disk configured to prevent a control line fluid from passing through the port to the setting chamber until a first predetermined fluid pressure is achieved in the control line, the first predetermined fluid pressure being a burst pressure of the first rupture disk.
 2. The downhole tool of claim 1, wherein the downhole tool is a multi-string packer.
 3. The downhole tool of claim 1, wherein the burst pressure of the first rupture disk is in a range of 500 psi to 10,000 psi.
 4. The downhole tool of claim 1, wherein the burst pressure of the first rupture disk is in a range of 2,000 psi to 5,000 psi.
 5. The downhole tool of claim 4, the burst pressure of the first rupture disk being in a range of 3,000 psi to 4,000 psi.
 6. The downhole tool of claim 5, the burst pressure of the first rupture disk being in a range of 3,200 psi to 3,600 psi.
 7. The downhole tool of claim 1, wherein the control line fluid is hydraulic fluid.
 8. The downhole tool of claim 1, further comprising the control line including a second rupture disk configured to prevent the control line fluid from passing through the port to the setting chamber until a second predetermined fluid pressure is achieved in the control line, the second predetermined fluid pressure being a burst pressure of the second rupture disk.
 9. The downhole tool of claim 8, the first and second rupture disks having a same burst pressure.
 10. The downhole tool of claim 8, the first and second rupture disks having a different burst pressure.
 11. A method of actuating a downhole tool within a wellbore, the method comprising: connecting a control line of the downhole tool to a pump located at surface; the control line including a port configured for fluid communication with a setting chamber of the downhole tool, the setting chamber configured to actuate at least one tool set feature of the downhole tool; running the downhole tool to a desired depth within the wellbore; filling the control line with a control line fluid; pressurizing, by way of the pump, the control line fluid to a first predetermined fluid pressure; preventing the control line fluid from passing through the port to the setting chamber until the first predetermined fluid pressure is achieved in the control line, the preventing being done by way of a first rupture disk having a predetermined burst pressure equal to the first predetermined fluid pressure; and after the first rupture disk bursts, the setting chamber moving in response to the control line fluid and actuating the at least one tool set feature.
 12. The method of claim 11, wherein the downhole tool is a multi-string packer.
 13. The method of claim 11, wherein the burst pressure of the first rupture disk is in a range of 500 psi to 10,000 psi.
 14. The method of claim 11, wherein the burst pressure of the first rupture disk is in a range of 2,000 psi to 5,000 psi.
 15. The method of claim 11, the burst pressure of the first rupture disk being in a range of 3,000 psi to 4,000 psi.
 16. The method of claim 15, the burst pressure of the first rupture disk being in a range of 3,200 psi to 3,600 psi.
 17. The method of claim 11, wherein the control line fluid is hydraulic fluid.
 18. The method of claim 11, wherein the downhole tool further comprises: the control line including a second rupture disk configured to prevent the control line fluid from passing through the port to the setting chamber until a second predetermined fluid pressure is achieved in the control line, the second predetermined fluid pressure being a burst pressure of the second rupture disk.
 19. The method of claim 18, wherein the first and second rupture disks having a same burst pressure.
 20. The method of claim 18, wherein the first and second rupture disks having a different burst pressure. 